INDUCTION Heating Systems


Master Controller v3+

Multifunction Heating Process Controller







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  • Programming and management of up to two independent heating stations, consisting of: CEIA Power Cube Generator; CEIA SH/SLE series non-contact temperature sensor or external thermocouples; automatic solder dispenser; antioxidant gas diffuser
  • High-definition graphic display
  • Internal memory and removable SDC Card containing up to 100 work programs
  • Multiple interface Capability including: Industrial current/voltage I/O; Field Bus; RS-232; up to 22 input and 22 output
  • Validation and Reporting of each heating cycle for Production Quality Control and Certification
  • “STATUS” key for immediate reading of main Generator working parameters
  • “QUICK ACCESS” key for fast programming of user defined parameters

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Master Controller v3+

The Master Controller V3+ is a multifunction industrial control unit, designed for automatic management of programmable heating processes.

Description

Master Controller v3+ - detail

The Master Controller V3+ is equipped with integrated Data Log and Web Server system. It is possible to perform automatic data storage, for a proper process quality control, monitoring heating temperatures, output power, frequency, voltage and inductor current.
An Ethernet TCP/IP port allows access to the internal web server of the Master Controller for remote programming settings and interface with SCADA / DCS systems.
Thanks to the Thermal Profile Monitoring software, coupled with the new CEIA SH15/SLE Optical Pyrometers, the user is now able to set specific temperature profiles, monitor and certify the heating process of each production item.

For more than 30 years CEIA has been manufacturing Generators and Control units for induction heating processes characterized by very high efficiency and minimum operating costs. CEIA’s unique technological solutions allow the manufacturing of power equipment with compact size, extremely high-energy efficiency and long-term reliability.

Thanks to the experience achieved in the field, and to the continuous R&D activities, CEIA is now proud to introduce the Master Controller V3+.

The Standard Controller version comes with a set of predefined programs. All operating parameters for each phase of the heating cycle can be programmed within a wide range of values.

This allows maximum flexibility in setting the heating and cooling times, the power supplied by the induction generators, the operating temperatures for the piece being worked on and the quantity and feed speed of the soldering wire.

A wide range of digital and analog I/O signals, a fieldbus and an RS-232 serial interface allow connection to PLC, PC or external logic for remote loading and running of preset and user-defined heating programs.

The isolated inputs have programmable P/N logic, while the isolated outputs use a programmable auxiliary voltage of 12/24 V.

Specifications

Heating system set-up

  • Alternating between the two heads (if connected to a single Power Cube generator)
  • Simultaneously on two heads (if connected to two Power Cube generators)
  • Capable of driving Power Cube generators in continuous operation
Management and Control
  • Activation of cycle: via external contact, RS-232 or Fieldbus interface
  • Control and Time Programming of 2 antioxidant gas diffusers, 2 heating heads and 2 wire dispensers
  • Available Settings: heating power; heating temperature (resolution 0,1°C); wire quantity and speed; antioxidant gas supply times; maximum solder force; wire feeder; piston advance delay
  • Control of the temperature of the article being processed: via optical temperature sensors, thermocouple or external sensors
  • SH15/SLE sample rate: 0.5 milliseconds
  • SH15/SLE time constant: 0.1 milliseconds
Functioning Modes
  • Manual
  • TIMER A: fully time-programmable cycle phases with controlled-temperature holding time
  • TIMER B: fully time-programmable cycle phases with programmable heating time and optional temperature control
  • TIMER C: fully time-programmable cycle phases, heating programmable with two times and two power levels
  • SYNCHRONISED: as TIMER A with holding time synchronised by an external event
  • FULL AUTO: as TIMER A, with management of the automatic solder wire feeder
  • FULL AUTO 2 WIRES: as Full auto, with the possibility of applying two independent solder wire feeders at the same soldering point (available only with –TS option)
  • THERMAL PROFILE: functioning with thermal profile (available only with -TP option)
  • THERMAL PROFILE 2 WIRES: as THERMAL PROFILE, with the possibility of applying two independent solder wire feeders at the same soldering point (available only with –TS and -TP option)
Control Inputs
  • 2 inputs for the connection of CEIA optical temperature sensors
  • 2 insulated digital inputs for connecting the cycle activation pedals
  • 2 insulated digital inputs for halting the operating cycle
  • 4 0-10V (or 0-20 mA, or 4-20mA) inputs (2 used for power control and 2 for temperature control)
  • 2 insulated inputs (RS232) for connection to external programmable units
  • 1 plug for a Field Bus module (accessory)
  • 6 insulated auxiliary digital inputs
  • 2 solder wire dispenser encoder inputs
  • 2 “wire present” inputs
  • 2 insulated digital inputs for starting a special cycle in manual mode
Outputs for Activation of External Slave Devices
  • 2 serial outputs for connecting and managing two independent Power Cube generators
  • 2 outputs for activation of antioxidant gas diffusers
  • 2 outputs for “Generator ON” signals
  • 2 outputs for “Temperature reached” signals
  • 2 outputs for activation of rapid cooling gas diffusers
  • 2 outputs for “End of cycle” signals
  • 2 output for system ready signal (relay output)
  • 2 0-10V (or 0-20 mA, or 4-20mA) outputs for temperature reading
  • 2 0-10V (or 0-20 mA, or 4-20mA) outputs for power reading
  • 2 solder wire dispenser driver outputs
  • 2 auxiliaries open collector outputs
Self-Diagnosis
  • Check of temperature and on the cooling water presence
  • Correct inductor dimensioning check
  • Internal malfunction
  • Working cycle malfunction
  • Reading/writing malfunction of internal memory cells
  • Inductor short circuit
  • Reading/writing malfunction of Program Card memory cells
  • Power Cube missed connection
  • Generators parameter screenshot
  • Supply voltage too low
  • Supply voltage too high
  • Soldering wire presence
  • Phase missing (if connected to 90, 180, 360 and 720 Power Cube Generators)
  • Programming access control through a password
Internal Memory
  • 100 sets of working parameters
  • 100 different storable thermal processes made of up to 20 segments per process (TP versions)
Removable Data Flash Card
  • 100 sets of working parameters storable on each card
  • 100 different storable thermal processes made of up to 20 segments per process (TP versions)
Power Supply and Power
  • Power supply voltage: 195-255 Vac, 1~ 50/60 Hz
  • Maximum absorbed power: 60 W
Operating Conditions
  • Operating temperature: + 5 to + 55 °C
  • Storage temperature: - 25 to + 70 °C
  • Relative humidity: 0-95% (without condensation)
Container
  • Stainless steel construction
  • Dimensions (WxDxH): 275 mm x 265 mm x 140 mm
  • Weight: 6 kg
Safety Features
  • Insulation from the mains voltage
  • Low operating voltage; no risk for the operator
  • Complies with international standards currently applicable for Electrical Safety (EN 60204-1) and Electromagnetic Compatibility (EN 61000-6-2, EN 61000-6-4)

Applications

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